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June 25, 2015 06:00 pm

New Manufacturing Technique Halves Cost of Lithium-Ion Batteries

An anonymous reader writes: Experts in materials science at MIT have developed a new process for creating lithium-ion batteries that will drop the associated production costs by half. The researchers say fundamental battery construction techniques have been refined over the past two decades, but not re-thought. "The new battery design is a hybrid between flow batteries and conventional solid ones: In this version, while the electrode material does not flow, it is composed of a similar semisolid, colloidal suspension of particles. Chiang and Carter refer to this as a 'semisolid battery.' This approach greatly simplifies manufacturing, and also makes batteries that are flexible and resistant to damage, says Chiang. ... Instead of the standard method of applying liquid coatings to a roll of backing material, and then having to wait for that material to dry before it can move to the next manufacturing step, the new process keeps the electrode material in a liquid state and requires no drying stage at all. Using fewer, thicker electrodes, the system reduces the conventional battery architecture's number of distinct layers, as well as the amount of nonfunctional material in the structure, by 80 percent."

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